Connector with shaft and cylindrical base extending from flange

ABSTRACT

The connector is configured to couple a first section and a second section of an e-vaping device, and the connector includes a flange with a first end and a second end, a shaft extending from the first end of the flange, an outer shelf being formed by a portion of the first end of the flange, a cylindrical base extending from the second end of the flange, and an inner shelf within the connector, the cylindrical base and the inner shelf at least partially defining a longitudinal opening, the flange defining at least one first notch, the at least one first notch at least partially along the second end of the flange.

PRIORITY CLAIM

This application is a Divisional of U.S. application Ser. No.15/980,329, filed May 15, 2018, which is a Divisional of U.S.application Ser. No. 15/492,290, filed Apr. 20, 2017, which is aContinuation of U.S. application Ser. No. 14/051,029, filed Oct. 10,2013, which claims priority as a Continuation to PCT Application No.PCT/US2012/033329, filed on Apr. 12, 2012, which claims priority to U.S.Provisional Patent Application No. 61/474,569, filed on Apr. 12, 2011,the disclosures of each of which are incorporated by reference in theirentirety.

BACKGROUND Field

This invention relates generally to electronic cigarettes and morespecifically to a battery connector for an electronic cigarette having aside air intake for improved air in-flow and out-flow through theelectronic cigarette.

Related Art

Electronic cigarettes are becoming a popular alternative to tobaccosmoking because of the many advantages that they offer. One of the mainreasons that they are popular is due to their similarities to tobaccosmoking. In fact, the closer that they are in providing the experienceof a traditional cigarette, the more likely they are to be accepted inthe market place.

An electronic cigarette typically comprises a battery, an atomizer, acontainer of smoke juice, a heating element and a power control circuit.The battery is used to power the circuit and the atomizer, where theatomizer heats the smoke juice to create smoke or vapor, which isinhaled by a user.

One example of an electronic cigarette (hereinafter an “ElectronicCigarette” or “E-cigarette”) is a “two-piece” device having a firstbattery section and a second atomizer section, wherein the atomizersection is detachable from the battery section.

An example of one such Electronic Cigarette is shown in FIGS. 1 and 2.In some embodiments, the battery section B contains a power cell, anairflow sensor, and a chipset (hereinafter referred to as, the Battery).In some embodiments, the atomizer section A contains a heating elementand a container of “smoke juice” which comprises flavorings and avaporizing base, such as glycol (hereinafter referred to as a“Cartomizer”). Typically, the Battery and Cartomizer are physically andelectrically connected by a threaded engagement. In some embodiments,the Battery has the “male” threaded portion and the Cartomizer has the“female” threaded portion, as shown in FIG. 2.

In the beginning stages of development of the Electronic Cigarette, itwas natural to copy the air flow and to mimic its path similar to theway it behaves in a traditional cigarette. In a tobacco cigarette, airenters the tip, which collects the smoke and enters the smoker's mouththrough the “filter.” Likewise, early E-cigarettes had one or morenotches at the tip of the Battery to allow air intake. Air would enterfrom the tip, pass through the entire Battery, and continue through theCartomizer, the vapor-producing portion of the E-cigarette, and enterthe smoker's mouth via the distal end of the Cartomizer, which functionsas a mouth piece.

A cross-section of an example of this arrangement can be seen in FIG. 3.As shown in FIG. 3, when air 104 is inhaled through the mouthpiece 100,air enters the tip of the cigarette, travels past an air flow sensor 102through the spaces provided around the sensor 102, and continues pastthe battery B (in this case a lithium cell.) It then goes through theopening in the axis of a post engaged with the Battery's male connector106, and straight into a post 108 engaged to the female connector of theCartomizer. The air is then inundated with atomized particles of liquidvapor and exits through the mouthpiece of the Cartomizer into thesmoker's mouth.

Heretofore, there has often been a specific problem with tip-intakeElectronic Cigarettes that the present invention aims to eliminate. Whenthe smoker exhales into a tip-intake battery Electronic Cigarette (assmokers often do), the vapors 104A from the mouth follow the reverse ofthe path described above—they flow inside the Battery towards the sensorand often condense causing the sensor to become clogged and fail. Theexhalation likewise causes excess liquid in the Cartomizer to follow thesame path into the Battery part towards the sensor, clogging it furtherand also causing it to fail. This also causes major difficulties inmass-production in terms of maintaining consistent air flow andconsistent sensitivity of the sensor from one Electronic Cigarette tothe next.

Therefore it is desirable to avoid bringing the intake air through theentire length of the Battery through its rear tip (hereinafter“Tip-Intake”), and instead to bring it in through its front side(hereinafter “Side-Intake”), at the point where the Battery andCartomizer sections meet.

However, it was always perceived as a necessity for the female threadedportion of the Cartomizer to have air slits at its edges when used inconjunction with a Side Intake Battery, because it was otherwisedifficult to mass-produce machined male threads that allow air intake atits base. As a result, if it was desirable to change the design of theE-cigarette from the Tip-Intake type to the Side-Intake type, one wouldnecessarily need to modify the female portion of the E-cigarette, i.e.the Cartomizer. Therefore, if it was desirable to make slits on theBattery section of the E-cigarette, one would need to redesign theentire E-cigarette so that the Battery section would be the femalethreaded portion and the Cartomizer section would be the male threadedportion. Additionally, one could never offer an option of interchangingthe male Battery section between the Tip-Intake type with theSide-Intake type, while maintaining compatibility with the same femaleportion, since in the latter, the female Cartomizer would require slitsat the engagement point, whereas in the former, the female Cartomizercould not have slits, otherwise the resulting airflow through theE-cigarette would be too great.

Accordingly, implementation of a Side-Intake Electronic Cigarette has,until the present invention, been considered an expensive andcomplicated proposition which would, by necessity, require redesign ofall parts of the device and eliminate the possibility ofbackwards-compatibility of the majority of internal parts of the device.

SUMMARY

The present invention resolves the above problems and provide an airintake path from the side of the E-cigarette via modification to themale Battery connector, without modifying the female Cartomizerconnector, while maintaining ease of manufacture—especially ease ofmachining the male Battery connector during mass production, andbackwards compatibility whereas the same un-slited female Cartomizercould be used together with the male Battery connector for both theTip-Intake and Side-Intake types of E-cigarettes.

The present invention also provides the possibility to create an airpath that will allow a silent air intake, unlike other Side-Intakesolutions that generate substantial hissing noise as the air enters fromthe side.

A cross-section of an Electronic Cigarette utilizing the Batteryconnector of the present invention is shown in FIG. 4. As can be seenthere, the spaces 110 around the sensor are blocked so no air flow takesplace through the cavity of the battery part. During inhalation, air 104enters from the side 112 of the Battery and enters the post 108 of theBattery B via a groove in the battery post. It then enters into theCartomizer A through the axial opening in the Cartomizer post and exitsthe Cartomizer into the smoker's mouth. Although there is also providedan opening 114 into the Battery through the battery post, there isminimal air or vapor flow through said opening 114 (hereinafter“pressure differential channel” 114) because the spaces 110 around thesensor are blocked. As a result, during inhalation, the sensor 102 candetect a pressure differential via said pressure differential channel114.

During exhalation, the vapors do not enter into the battery part towardsthe sensor; they travel out through the side vents, opposite to thedirection that air entered upon inhalation. Such a construction greatlyextends the life of the product.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is an assembled view of a typical two-piece electronic cigarette.

FIG. 2 is a disassembled view of a typical two-piece electroniccigarette.

FIG. 3 is a cross-sectional view of an electronic cigarette in the priorart showing inhaled and exhaled air paths.

FIG. 4 is a cross-sectional view of an electronic cigarette using thenovel connector herein described showing inhaled and exhaled air paths.

FIGS. 5-13 are alternative embodiments of the connector of the presentinvention showing various arrangements of side vent apertures.

FIGS. 14-15 illustrate an alternative embodiment of a connector of thepresent invention with a battery post of the present invention.

FIG. 16 is a cross-sectional view of an electronic cigarette using theconnector and battery post shown in FIGS. 13-15.

FIG. 17 illustrates an alternative embodiment of a battery post of thepresent invention.

FIG. 18 is a cross-sectional view of an electronic cigarette using theconnector of FIG. 13 and the battery post of FIG. 17.

DETAILED DESCRIPTION

The present invention concerns various embodiments of aBattery-Cartomizer connector for an Electronic Cigarette that creates anair-intake path that enters through the male connector (i.e. the Batterysection), without the need to modify the female connector (i.e. theCartomizer section) thereof. Accordingly, the present invention permitsflexibility of design and product diversification for the E-cigarettemanufacturer, maintains ease of manufacture and mass-production, andcreates additional advantages such as reducing noise and hissing duringair-intake (i.e. a “puff or “drag”).

FIGS. 5-13 depict various embodiments of the connector of the presentinvention. It is understood that these figures depict a sectional viewof an E-cigarette connector 1, which joins the Battery section to theCartomizer section by a threaded engagement. As shown in FIGS. 5-13, itis intended that the male Battery connector M at the proximal end 3 ofthe connector mates to a female portion of a Cartomizer, and the distalend 5 of the connector is attached, through a pressure or friction fit,or through other suitable means, to the Battery portion B (not shown)and functions as a “cap” thereof.

In some embodiments of the present invention, an air intake path startsat the outer circumference of the connector 1 between the Battery andthe Cartomizer of the E-cigarette, running inside notch 9 on connector1. The air is thus brought into the Battery through grooves 10 formed onthe attachment (i.e., non-threaded) distal end 5 of the connector. Onceinside the battery, the air path loops around and exits the Batteryhousing towards the Cartomizer, via a hole along the central axis ofconnector 1. In accordance with the desired air-intake path, notch 9 iscut out on the side of connector 1 at strategic location and withstrategic geometry.

In most E-cigarettes, connector 1 has a flange 7 that appears from theoutside as a metallic ring when the separate parts of the E-cigaretteare screwed together, like that shown in FIG. 1. The resulting ring isusually very thin, and has little purpose other than cosmetic—to createa decorative divider between the two major parts of the E-cigarette(i.e. the Battery section and the Cartomizer section) and to cover theinside edge of the Battery housing. Cutting into this ring or removing aportion of it to create the desired air-intake characteristics of thepresent invention would expose the dull edge of the Battery housing anddetracts from the esthetics of the product. However, in some embodimentsof the present invention, the thickness of the flange is increased sothat a portion of it can be cut or milled away, resulting in notch 9,while the remaining portion of the flange thickness will still retainthe aesthetic design and still cover the internal edge of the housing.

Accordingly, as shown in FIG. 5, in some embodiments of connector 1,notch 9 begins at the outer perimeter of the flange 7, toward distal end5 and travels toward the center axis of flange 7, resulting in arectangular shape.

In some embodiments, such as in FIG. 6, aperture 11 is bored through thewall of the distal end 5 of connector 1 at substantially the same radiallocation as notch 9. This configuration increases the air-intake volume,permitting less-constricted air flow through the connector 1 and theBattery section.

In some embodiments, such as in FIG. 7, slot 13 is milled along thecurved wall of the distal end 5 of connector 1, with notch 9 locatedsubstantially across from the center of slot 13, radially. As shown,slot 13 is oriented perpendicular to the longitudinal axis of connector1.

In some embodiments, such as in FIG. 8, channel 15 is milled across theouter surface of the distal end 5 of connector 1, beginning at notch 9and terminating at the end of distal end 5. In this configuration, notch9 has a substantially curved profile that transitions uniformly intochannel 15. In this configuration, channel 15 is milled substantiallyparallel to the longitudinal axis of connector 1.

In some embodiments, such as in FIG. 9, fanned channel 17 is milledacross the outer surface of the distal end 5 of connector 1, beginningat notch 9 and terminating at the end of distal end 5. Notch 9 has asubstantially curved profile that transitions into fanned channel 17.Fanned channel 17 is milled substantially parallel to the longitudinalaxis of connector 1.

In some embodiments, such as in FIG. 10, channel 19 is milled away allaround the outer circumference of flange 7, along its distal edge. Thepurpose of channel 19 is to allow for air intake even when a userhappens to hold his finger over notch 9 during smoking. When thathappens, air enters channel 19 and runs along the channel until itreaches and enters notch 9.

In some embodiments, such as in FIG. 11, channel 21 is milled away allaround the outer circumference of flange 7, substantially in the middleof the flange. Several apertures 23 are bored through the wall of theflange. The purpose of channel 21 is to allow for air intake even when auser holds his finger over an aperture 23 during smoking. When thathappens, air enters channel 21 and runs along the channel until itreaches and enters an aperture 23.

In some embodiments, such as in FIG. 12, notch 25 is cut out through thewall of flange 7 on the side of connector 1 at strategic location andwith strategic geometry. Slot 27 is cut out of the distal end 5 ofconnector 1, beginning at notch 25 and terminating at the end of distalend 5. In this configuration, notch 25 has a rectangular profile thattransitions uniformly into slot 27.

Another embodiment of the connector of the present invention is shown inFIGS. 13-15. FIG. 13 shows the connector without a battery post, FIG. 14shows the battery post and FIG. 15 shows the battery post and connectorassembled. As shown in FIG. 13, instead of a notch in the outerperimeter of the flange 7, toward distal end 5, perpendicular surfacechannels 30 are drilled on shelf 31 of flange 7. The channels continueand penetrate through the shaft 32 of connector 1 (in which threads arenot shown for purposes of clarity) at orifices 33 and continue throughinner shelf 45. The engaging battery post 34, shown in FIG. 14, includesa longitudinal orifice 35 (beginning on the surface of post head 37 andcontinuing longitudinally completely through the post) that forms thepressure differential channel, as well as a groove 36 which assists inguiding air inhaled or exhaled through perpendicular surface channel 30and orifice 33.

It should be noted here that although in FIG. 15 groove 36 is shownaligned with perpendicular surface channel 30 and orifice 33, becausethe outer diameter of post head 37 is smaller than the inner diameter ofshaft 32, such alignment is not necessary to allow for unimpeded airflow through connector 1.

The airflow 104 through the connector and battery post combination shownin FIGS. 13-15 is illustrated in FIG. 16. As shown in FIG. 16, onepossible draw-back of this arrangement is that upon exhalation, anyexcess fluid 116 (vapor, saliva, etc.) could be blown through orifice35, into the pressure differential channel and into the Battery B.

An alternative embodiment for a battery post designed to minimize thisproblem is shown in FIG. 17. As shown in this figure, there is noorifice drilled through post head 37. Rather, the air path to thepressure differential channel is created by channel 38 which is drilledbeneath groove 36 on the side 39 of post head 37. Channel 38perpendicularly intersected by the pressure differential channel (notshown) which is drilled longitudinally from battery post end 40.

The airflow through a connector such as that shown in FIG. 13 using thebattery post shown in FIG. 17 is illustrated in FIG. 18. As is shown inthis figure, there is no direct path for excess liquid 116 to migrateinto the Battery compartment B.

The connector 1 of the present invention has an additional majoradvantage in that those embodiments shown in FIGS. 5-18 allow for asubstantially silent air-intake without the excessive hissing or noiseassociated with other known E-cigarettes. Another major advantage of thepresent invention is its application in newly introduced V-Go and E-go(large-capacity electronic cigarettes) E-cigarettes. V-go and E-goE-cigarettes, which almost always have a side-intake, cannot be usedwith non-vented female Cartomizers. Heretofore manufacturers always hadto resort either to vented female Cartomizers or non-vented maleCartomizers. However, with the present invention, it is possible tocreate V-go and E-go E-cigarettes that will be interchangeable withTip-Intake E-cigarettes so that they are compatible with the sameexisting female unvented Cartomizers, without the need to modify theCartomizers.

It should be appreciated that although the above-described embodimentsdemonstrate that some embodiments of the present invention are designedsuch that the Battery comprises the “male” connection and the Cartomizercomprises the “female” connection, the reverse configuration may beequally suitable, depending on design requirements. Accordingly, theCartomizer may comprise the “male” connection and the Battery maycomprise the “female” connection.

It will be understood that the preferred embodiments of the presentinvention have been disclosed by way of example and that othermodifications and alterations may occur to those skilled in the artwithout departing from the scope of the disclosure herein.

1. (canceled)
 2. A connector configured to couple a first section and asecond section of an e-vaping device, the connector comprising: a flangewith a first end and a second end; a shaft extending from the first endof the flange, an outer shelf being formed by a portion of the first endof the flange; a cylindrical base extending from the second end of theflange; and an inner shelf within the connector, the cylindrical baseand the inner shelf at least partially defining a longitudinal opening,the flange defining at least one first notch, the at least one firstnotch at least partially along the second end of the flange.
 3. Theconnector of claim 2, wherein the at least one first notch at leastpartially defines at least one first entrance in an outer surface of theflange, and the at least one first entrance is an air inlet for at leastone first air passage that is in fluid communication with thelongitudinal opening.
 4. The connector of claim 3, wherein the innershelf includes a first surface, and the first surface at least partiallydefines an outlet of the at least one first air passage.
 5. Theconnector of claim 4, wherein the first end of the flange defines afirst annular surface that faces the shaft, and the first surface isaligned with the first annular surface.
 6. The connector of claim 3,wherein the cylindrical base includes sidewalls, and the sidewalls atleast partially define the at least one first entrance.
 7. The connectorof claim 3, wherein the cylindrical base includes sidewalls, and thesidewalls and the flange at least partially define the at least onefirst air passage.
 8. The connector of claim 3, wherein the at least onefirst notch at least partially defines at least one first entrance in anouter surface of the flange, and the at least one first entrance is anair inlet for at least one first air passage that is configured to be influid communication with the longitudinal opening once the connectorconnects the first section to the second section.
 9. The connector ofclaim 8, wherein the cylindrical base includes sidewalls, and thesidewalls at least partially define the at least one first entrance. 10.The connector of claim 3, wherein the at least one first air passage hasa first longitudinal length that extends in a first direction, and thefirst direction traverses through an imaginary cross-sectional line ofthe connector, the imaginary cross-sectional line passing through alongitudinal axis of the connector.
 11. The connector of claim 2,wherein the cylindrical base includes a third end and a fourth end, thethird end is connected to the flange, and the fourth end is tapered. 12.The connector of claim 3, wherein the outer surface of the flange is awidest portion of the connector along an imaginary cross-sectional lineof the connector, the imaginary cross-sectional line passing through alongitudinal axis of the connector.
 13. The connector of claim 2,wherein the inner shelf is configured to hold an electrical contact. 14.The connector of claim 13, further comprising: the electrical contact,wherein the electrical contact is on an end of the first section. 15.The connector of claim 3, wherein the cylindrical base is configured toconnect to the first section, and the shaft is configured to beselectively connectable to the second section.
 16. The connector ofclaim 15, wherein the connector is configured to establish an airflowpath once the connector is connected to the first section and the secondsection, the airflow path causing incoming air to enter the longitudinalopening through the at least one first air passage.
 17. The connector ofclaim 3, wherein the outer surface of the flange is a widest portion ofthe connector along an imaginary cross-sectional line of the connector,the imaginary cross-sectional line passing through a longitudinal axisof the connector, and a first diameter of the cylindrical base isgreater than a second diameter of the shaft.
 18. The connector of claim3, wherein the at least one first air passage includes a first airpassage and a second air passage that are equidistantly spaced apart onthe flange.
 19. The connector of claim 18, wherein the first air passageand the second air passage each traverse through the flange at an anglethat is about perpendicular to the outer surface of the flange.
 20. Ane-vaping device, comprising: the connector of claim 3; the firstsection, the cylindrical base of the connector being connected to thefirst section; and the second section, the shaft of the connector beingconfigured to be selectively connectable to the second section toconnect the first section to the second section.
 21. The e-vaping deviceof claim 20, wherein the first section is a power section; and thesecond section is a cartridge.
 22. The e-vaping device of claim 20,wherein the at least one first notch and a distal end of a first housingof the first section combine to at least partially define the at leastone first entrance.
 23. The e-vaping device of claim 22, wherein theouter surface of the flange, the first housing of the first section anda second housing of the second section combine to form an outer surfaceof the e-vaping device once the connector connects the first section tothe second section.